Surgical saw blade coupler

ABSTRACT

A surgical saw blade coupler for removably holding a surgical saw blade. The surgical saw blade may be of various shaped and sizes, including, but not limited to straight or crescentic. The surgical saw blade coupler includes a cap, a pin and a driver. The driver is rotatably coupled to a motor within a housing. The cap and the pin form a slot which receives a first end of the surgical saw blade. The cap and the pin also form a groove for receiving a back edge of the surgical saw blade. The surgical saw blade coupler is moveable between an open position in which the surgical saw blade may be removed, exchanged or inserted, and a closed position.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Application Serial No. 60/425,461, filed Nov. 12, 2002 (Attorney Docket No: 60,210-144).

FIELD OF THE INVENTION

[0002] The present invention relates generally to powered surgical cutting devices, and more particularly, to a surgical saw blade coupler for releasably holding a surgical saw blade.

BACKGROUND OF THE INVENTION

[0003] It is common to use powered surgical cutting devices during surgical procedures. Generally, these devices have a handle. An electric or pneumatic motor is contained within the handle. The motor drives, in a cyclical fashion, a driver. One end of a surgical blade is releasably coupled to the driver. The other end of the blade includes a cutting edge with a plurality of teeth. The surgical blade may be of various shapes, e.g., for crescentic or straight and, typically, may be mounted to the driver in various positions. Commonly, the surgical blades are interchangeable and disposable.

[0004] Generally, a clamping structure is used to releasably couple the blade to the driver. When force is applied to the cutting edge of the surgical blade the force is transferred to the opposite end of the blade. This may have the effect of compromising the clamping structure, resulting in an unintentional release or slippage of the saw blade.

[0005] One device aimed at overcoming this problem is disclosed in U.S. Pat. No. 5,658,304 issued Aug. 19, 1997 to Joepert Lim (the '304 patent). The device disclosed in the Lim patent includes a cutting element with two flanges and a handpiece with a base surface and a groove adjacent the base surface. When coupled together, one of the flanges engages the base surface and the other flange engages the groove. However, the addition of a second flange to the saw blade, increases the complexity of the saw blade and thus the cost of the saw blade.

[0006] The present invention is aimed at one or more of the problems as set forth above.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0007] A surgical saw blade coupler for removably holding a surgical saw blade. The surgical saw blade may be of various shapes and sizes, including, but not limited to straight or crescentic. The surgical saw blade coupler includes a cap, a pin and a driver. The driver is rotatably coupled to a motor within a housing. The cap and the pin form a slot which receives a first end of the surgical saw blade. The cap and the pin also form a groove for receiving a back edge of the surgical saw blade. The surgical saw blade coupler is moveable between an open position in which the surgical saw blade may be removed, exchanged or inserted, and a closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0009]FIG. 1 is an isometric view of a surgical saw blade coupler for use with a surgical saw blade, according to an embodiment of the present invention;

[0010]FIG. 2 is side view of the surgical saw blade coupler of FIG. 1;

[0011]FIG. 3 is a cut-away drawing of the surgical saw blade coupler of FIG. 1 and a straight saw blade;

[0012]FIG. 4 is a view of a first end portion of a saw blade for use with the surgical saw blade coupler of FIG. 1;

[0013]FIG. 5 is a top down view of a pin of the surgical saw blade coupler of FIG. 1, according to an embodiment of the present invention;

[0014]FIG. 6 is a side view of the pin of FIG. 5;

[0015]FIG. 7 is an enlarged view of the surgical saw blade coupler of FIG. 1 in an open position;

[0016]FIG. 8 is a top view of a driver of the surgical saw blade coupler of FIG. 1, according to an embodiment of the present invention;

[0017]FIG. 9 is a side view of the driver of FIG. 8;

[0018]FIG. 10 is a side view of the surgical saw blade coupler and a crescentic saw blade, according to an embodiment of the present invention;

[0019]FIG. 11 is a cut away view of the surgical saw blade coupler and the crescentic saw blade of FIG. 10;

[0020]FIG. 12 is an isometric view of the crescentic saw blade of FIG. 11;

[0021]FIG. 13 is a bottom view of the crescentic saw blade of FIG. 11; and,

[0022]FIG. 14 is an enlarged view of a portion of the surgical saw blade coupler of FIG. 1, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] With reference to the drawings, and in operation, the present invention provides a surgical saw blade coupler 10 for use with a surgical saw blade 12. As discussed below, the surgical saw blade 12 may be of various shapes and sizes, such as a crescentic blade or a straight blade. The surgical saw blade coupler 10 is partially, rotatably contained within a housing 14 and is coupled to a motor (not shown) contained within the housing 14. The motor may be of any suitable type, e.g., pneumatic or electrical. The motor provides motion to the surgical saw blade 12. In one embodiment, the motor provides cyclical linear motion. In another embodiment, the motor provides cyclical angular motion (as shown by the arrow 16 in FIG. 1).

[0024] With specific reference to FIGS. 1, 2, 3 and 7, in one embodiment, the coupler 10 includes a cap 18, a pin 20, and a driver 22. The coupler 10 is movable to and between an open position, as shown, in FIGS. 1, 2 and 7, and a closed position, as shown in FIG. 3. When the coupler 10 is in the open position, the surgical saw blade 12 may be removed, positioned or inserted into the coupler 10. The coupler 10 may be moved to the closed position to secure the surgical saw blade 12 in place.

[0025] As shown in FIGS. 5 and 6, the pin 20 has an upper portion 24, a circular portion 26, and a bottom portion 28. The upper portion 24 has a cylindrical shape including a top portion 30 and a coupling portion 32. The top portion 30 has a slightly smaller diameter then the coupling portion 32. As shown in FIGS. 1 and 7, the cap 18 includes a cap aperture 34 which receives and secures the coupling portion 32. In one embodiment, the pin 20 and the cap 18 are secured together by a press fit between the cap 18 and the coupling portion 32 of the pin 20.

[0026] Returning to FIGS. 5 and 6, the circular portion 26 has a circular outer edge 36. As shown, the circular portion 26 includes a plurality of pin apertures 38. In the illustrated embodiment, the circular portion 26 includes four pin apertures 38A, 38B, 38C, 38D. In one embodiment, each aperture 38 has first and second arcuate sides 40A, 40B and first and second linear sides 42A, 42B.

[0027] When joined together, the cap 18 and the circular portion 26 of the pin 20 form a coupler slot 44 which receives the surgical saw blade 12.

[0028] With reference to FIGS. 2, 7, 8 and 9, the driver 22 includes a driven portion 46 and a locking portion 48. In the illustrated embodiment, the driven portion 46 includes first and second prongs and is adapted to couple with the motor and to translate motion from the motor to the coupler 10, and hence, the surgical saw blade 12.

[0029] The locking portion 48 includes an upper surface 50 and at least one locking member 52 located on the upper surface 50.

[0030] In the illustrated embodiment, the locking portion 48 includes four engaging members 52A, 52B, 52C, 52D. As shown, each engaging member 52 has a general curved U shape. Each engaging member 52 further has first and second engaging prongs 54A, 54B and a central engaging portion 56.

[0031] When the coupler 10 is in the closed position, portions of the first and second engaging prongs 54A, 54B and the central engaging portion 56 of each engaging member 52 fit through one of the pin apertures 38 of the pin 20.

[0032] In one illustrated embodiment, the surgical saw blade 12 is a straight blade, as shown in FIGS. 3 and 4. The surgical saw blade 12 has a first end 58 which slides into the coupler slot 44 and is locked into place by the coupler 10 (see below). A second end 60 includes a cutting edge 62 having a plurality of teeth 64.

[0033] With particular reference to FIG. 4, the first end 58 includes a blade slot 66 and a plurality of blade apertures 68. In the illustrated embodiment, the first end 58 includes five blade apertures 68A, 68B, 68C, 68D, 68E. The blade apertures 68 are shaped to receive one of the engaging prongs 54 of the locking members 52.

[0034] With the coupler 10 in the open position, the surgical saw blade 12 may be inserted into the coupler slot 44 formed between the cap 18 and the pin 20. The blade slot 66 slips around the coupling portion 32 of the pin 20. The surgical saw blade 12 may be positioned within the coupler slot 44 such that the blade apertures 68 align with the engaging prongs 54 of the locking members 52.

[0035] Once the surgical saw blade 12 is in position, the coupler 10 may be closed or moved to the closed position. With particular reference to FIG. 14, which is an enlarged view of the coupler 10 and surgical saw blade 12, when the coupler 10 is in the closed position. As shown, the coupling portion 32 of the pin 20 forms a ledge 70. The cap 18 rests on the ledge 70 forming a back portion 72 of the coupler slot 44 with the circular portion 26 of the pin 20. The surgical saw blade 12 is inserted into the coupler slot 44.

[0036] The first end 58 of the surgical saw blade 12 has a width, X, which is slightly smaller than the width, Y, of the second groove 74. For example, in one embodiment, the surgical saw blade 12 has a width of 0.025 inches and the second groove 74 has a width of 0.027 inches.

[0037] When a force is applied to the surgical blade 12 in the direction of arrow F1 or F2, the surgical saw blade 12 tilts within the coupler slot 44. While the surgical saw blade 12 is tilted it is in contact with the coupler slot 44 at two points. One of the corners of the back portion 72 of the surgical saw blade 12 is in contact with either the cap 18 or the pin 20. And a point on the opposite side of the surgical saw blade 12 is in contact with the other of the cap 18 or the pin 20. This helps to prevent further movement of the surgical saw blade 12 within the coupler 10 and to prevent the applied force from opening the coupler 10.

[0038] Additionally, the locking members 52 are inserted through the pin apertures 38 in the pin 20. Furthermore, at least one of the engaging prongs 54 is inserted through one of the blade apertures 68 in the first end 58 of the surgical saw blade 12. In the illustrated embodiment, five of the engaging prongs 54 are inserted through the blade apertures 68 in the first end 58 of the surgical saw blade 12. First and second pairs of these engaging prongs 54 are associated with two locking members 52. An upper surface of the central engaging portion 56 engages or is contact with a surface of the first end 58 of the surgical saw blade 12. This serves to lock the surgical saw blade 12 in place between the cap 18 and the pin 20 when the surgical saw blade coupler 10 is in the closed position.

[0039] With reference to FIGS. 10, 11, 12, and 13, the surgical saw blade 12 is shown as a crescentic saw blade 12′. The crescentic saw blade 12′ has a curved body portion 76 with a first end 58′ and a second end 60′. The first end 58′ has a cutting edge 62′ with a plurality of teeth 64′. A base 78 is connected to the second end 60′ of the crescentic saw blade 12′. The base 78 includes a blade slot 66′ and a plurality of teeth 64′. The base 78 is similar to the second end 60 of the straight blade 12 detailed above and operates in a similar manner.

[0040] In one embodiment, the surgical saw blade 12, 12′ are composed from stainless steel.

[0041] Returning to FIG. 3, the coupler 10 further includes a bearing 80 inserted into a housing aperture 82 within the housing 14. A cup 84 is inserted within the center of the bearing 80. The cup 84 has a first end 86 and a second end 88. The first end 86 includes a cup aperture 90. A lip 92 is located at the second end 88. The bottom portion 28 of the pin 20 passes through the cup aperture 90. The lip 92 rests against the bearing 82 and prevents further inward (to the left in FIG. 3) movement of the cup 84. A button 94 having a press fit with the bottom portion 28 of the pin 20 is inserted between the bottom portion 28 and the cup 84. A biasing spring 96 is located between the button 94 and the first end 86 of the cup 84. The biasing spring 96 acts against the button 94, and thus, the pin 20, to bias the pin 20 to close the coupler 10. In the illustrated embodiment, the biasing spring 96 acts to close the coupler 10. To insert, remain, and/or exchange blades 12, 12′ the cap 18 and pin 20 are manually opened (against the force exerted by the spring 96) by pushing on the button 94. After the blade 12, 12′ is removed and/or inserted, the spring 96 acts to close the coupler 10, thus locking the blade 12, 12′ in place. 

What is claimed is:
 1. A surgical saw blade coupler coupled to a motor for removably holding a surgical saw blade, the coupler comprising: a housing for rotatably receiving the coupler and having a housing aperture and a bearing disposed in the housing aperture; a cup disposed in the bearing and including a first end defining a cup aperture and a second end having a lip for limiting inward movement of the cup through the housing aperture; a driver coupled to the motor for translating motion from the motor to the blade via the coupler; a pin having an upper portion and a bottom portion and being attached to the driver; and a cap disposed on the pin defining a coupler slot there between for receiving the surgical saw blade having a first end and a second end wherein the coupler is movable to and between an open position wherein the blade may be removed from, positioned within or inserted into the coupler, and a closed position for securing the blade within the coupler.
 2. The coupler as set forth in claim 1 the upper portion including a top portion having a first diameter.
 3. The coupler as set forth in claim 2 the upper portion including a coupling portion having a second diameter.
 4. The coupler as set forth in claim 3 the first diameter being smaller than the second diameter.
 5. The coupler as set forth in claim 4 the cap including a cap aperture for receiving and securing the coupling portion.
 6. The coupler as set forth in claim 4 the cap and the coupling portion are being affixed via a press fit.
 7. The coupler as set forth in claim 1 the upper portion being cylindrical.
 8. The coupler as set forth in claim 1 the pin including a circular portion having a circular outer edge.
 9. The coupler as set forth in claim 8 the circular portion including a plurality of pin apertures.
 10. The coupler as set forth in claim 9 each of the plurality of pin apertures including first and second arcuate sides and first and second linear sides.
 11. The coupler as set forth in claim 9 the circular portion including four pin apertures.
 12. The coupler as set forth in claim 1 the driver including a driven portion for coupling the driver to the motor for translating motion from the motor to the blade via the coupler.
 13. The coupler as set forth in claim 12 the driven portion including a first prong and a second prong.
 14. The coupler as set forth in claim 12 the driver including a locking portion.
 15. The coupler as set forth in claim 14 the locking portion including an upper surface having at least one locking member disposed thereon.
 16. The coupler as set forth in claim 15 each locking member being U-shaped.
 17. The coupler as set forth in claim 15 the locking portion including four locking members.
 18. The coupler as set forth in claim 15 each locking member including a first engaging prong, a second engaging prong and a central engaging portion.
 19. The coupler as set forth in claim 18 the first end including a blade slot and a plurality of blade apertures for receiving one of the engaging prongs.
 20. The coupler as set forth in claim 19 including the blade disposed in the coupler slot within the coupler in the open position and having the blade slot disposed about the coupling portion with the blade apertures in alignment with the engaging prongs.
 21. The coupler as set forth in claim 19 each of the plurality of pin apertures for receiving portions of the first and second engaging prongs and the central engaging portion and securing the blade within the coupler in the closed position.
 22. The coupler as set forth in claim 19 the coupling portion defining a ledge for receiving the cap and forming a back portion disposed on the coupler slot for receiving the blade.
 23. The coupler as set forth in claim 1 the second end including a cutting edge having a plurality of teeth.
 24. The coupler as set forth in claim 1 wherein the blade is a straight blade.
 25. The coupler as set forth in claim 1 wherein the blade is a crescentic blade.
 26. The coupler as set forth in claim 1 wherein the blade is a fan blade,
 27. The coupler as set forth in claim 1 wherein the blade is an oral blade. 